1

“DESIGN & FABRICATION OF PEDAL POWERED

WASHING MACHINE”

A Project Report

Submitted in partial fulfillment for the

Award of the degree of

BACHELOR OF TECHONOLOGY

IN

MECHANICAL ENGINEERING

Submitted by

DHANANJAY KUMAR GUPTA (1264540033)

SAURABH DIXIT (1264540068)

RISHABH DIXIT (1264540063)

HIMANSHU PRATAP SINGH (1264540037)

ASHISH KUMAR (1264540023)

UNDER THE SUPERVISION OF

Mr. M. K. PODDAR

(Assistant Professor)

IDEAL INSTITUTE OF MANAGEMENT & TECHNOLOGY, GHAZIABAD

Dr. A. P. J. ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW

(2015-2016)

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DECLARATION

We hereby declare that we are Student of Mechanical Engineering, IIMT, Ghaziabad.

We are working on project under the guidance of Mr. M. K.PODDAR Further, this work

has been submitted in full to obtained degree of the Bachelor of Technology that the

studies described in this report entitled “DESIGN & FABRICATION OF PEDAL

POWERED WASHING MACHINE” in subject Mechanical engineering is carried out

by us

NAME ROLL NO. SIGNATURE

Saurabh Dixit 1264540068

Dhananjay Kumar Gupta 1264540033

Himanshu Pratap Singh 1264540037

Ashish Kumar 1264540023

Rishabh Dixit 1264540063

Date:

3

IDEAL INSTITUTE OF MANAGEMENT & TECHNOLOGY, GHAZIABAD

Dr. A. P. J. ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW

(An ISO 9001:2008 Certified Institution)

Phone:- 0120-2767816, 0120-2767818, Fax:- 0120-2767352

Email:- info@idealinstitute.ac.in Website:- www.idealinstitute.ac.in

CERTIFICATE

This is to certify that project report entitled “DESIGN & FABRICATION OF PEDAL

POWERED WASHING MACHINE” which is being submitted by Dhananjay Kumar

Gupta, Saurabh Dixit , Rishabh Dixit, Himanshu Pratap Singh , Ashish Kumar

in partial fulfillment for the requirement for the award of the degree of Bachelor of

Technology in department of Mechanical Engineering of Ideal Institute of Management

and

Technology, Ghaziabad under Dr. A. P. J. Abdul Kalam Technical University, Lucknow.

They have worked under the guidance of Mr. M. K. PODDAR (Asst. Professor,

Department of Mechanical Engineering, IIMT, GZB) and have fulfilled the requirement

for the submission of the project. The matter embodied in this thesis is original and has not

been submitted for the award of any other degree.

Signature of Supervisor Signature of HOD Signature of External

Examiner

Mr. M. K. PODDAR Mr. K. K. GUPTA

Assistant Professor Assistant Professor

Deptt of Mech. Engg. Deptt of Mech. Engg.

Date-

4

ACKNOWLEDGEMENT

We express our deep sense of gratitude and indebtedness to HOD Mr. K . K. GUPTA,

Lucknow for giving us opportunity to carry out this project. With immense pleasure we

express our deep sense of gratitude and respectful to Mr. M. K. PODDAR (Assistant

Professor) who was guiding us by giving his valuable suggestions, constructive criticism

and encouragement, which helped us to keep our spirits high and to deal with problems.

His meticulous methodology, critical assessment and warm encouragement made it

possible for me to bring the work in its present shape.

We are sincerely thankful to all other members of FACULTY OF MECHANICAL, IIMT

for giving us time to time support in doing this project. We express a word of thanks to our

friends for their constant support, suggestions and encouragement during preparation of

this project. Finally, we thank God for giving us the loving siblings and affectionate

parents, who blessed us with everything all throughout our life. Our gratitude to them

cannot be expressed in words. To them we owe our wonderful today and a dream filled

tomorrow.

NAME ROLL NO. SIGNATURE

Saurabh dixit 1264540068

Dhananjay kumar gupta 1264540033

Himanshu pratap singh 1264540037

Ashish kumar 1264540023

Rishabh dixit 1264540063

Date:

5

ABSTRACT

Pedal power is the transfer of energy from a human source through the use of a foot pedal

and gear system. This technology is most commonly used for transportation and has been

used to propel bicycles for over a hundred years. Less commonly pedal power is used to

power agricultural and hand tools and even to generate electricity. Some applications

include pedal powered laptops, pedal powered grinders and pedal powered water wells.

This project concentrates on pedal powered washing machine. The basic Principle of this

machine is compound gear system; the concept of this Mechanism is that the pedaling is

converted into rotary motion.

Cloth washing is one of the essential parts of the life but it is considered undesirable

because of the involvement of efforts, time, energy and cost. Nowadays a wide variety of

washing machines are available in the market. All of the washing machines available in the

market are electric power driven and basic principle of their operation depends upon

creation of the turbulent flow of detergent around the dirty clothes. In our country where

approximately 70% population is living with very poor economic status, those people

cannot have a washing machine because of cost constraints and unavailability of electricity

due to any reason.

The present work is an attempt to develop a concept to make a cloth washing

mechanism which can meet out the requirements of above mentioned 70% population of

the nation. Working principle of this concept is no more different from available similar

type of machine with a difference driving mechanism of the machine. The objective of

bringing down the initial cost and operating cost of washing machine is almost achieved in

present work within the limitation of work as mentioned.

The main aim is to reduce the human effort for provides the light washing in the rural and

dark areas which are very far from the electricity and development. In our country where

approximately 70% population is living with very poor economic status, those people

cannot have a washing machine because of cost constraints and unavailability of electricity

due to any reason according to survey 2013-2014, there are approximate 25722 villages are

still not electrified, where 400 million people are suffering from this problem.

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NOMENCLATURE

S.NO. SYMBOL DESCRIPTION

1. rpm Rotation Per Minute

2. mm Milimeter

3. HP Horse Power

4. min Minute

5. W Watt

6. T Teeth of gear

7. lb Pounds

8. Kg Kilogram

9. F Fehrenheit

10. ac Alternating current

11. dc Direct current

12. ₨ Rupees

13. $ Dollar

14. °C Celsius

15. B\W Between

16. m Module of gear

17. I/P Input

7

18. O/P Output

19. Appx. Approximate

20. i.e. That is

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TABLE OF CONTENTS

Page No.

Declaration i

Certificate ii

Acknowledgement iii

Abstract iv

Nomenclature v

List of Contents vi

List of Table viii

List of Figure ix

CHAPTER 1: INTRODUCTION 1-4

1.1 THEORY 1-2

1.2 INNOVATION 3

1.3 EASE OF USE 3

1.4 NEED 4

CHAPTER 2: LITERATURE SURVEY 5-6

2.1 Literature survey of the pedal powered washing machine 5

2.2 Project Objectives 6

CHAPTER 3: DESIGN & CONSTRUCTION OF PPWM 7-21

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3.1 Components and their technical Features 7

3.1.1 Seat 7

3.1.2 Pedal arrangement 7

3.1.3 Gear 8

3.1.4 Bearing 9-10

3.1.5 Chain and sprocket 11

3.1.6 Catcher 15

3.1.7 Shaft 15

3.1.8 Shaft collar 16

3.1.9 Drum as a washing chamber 16

3.1.10 Cycle frame arrangement

3.1.11 Welding

18

3.1.12 Dimension of base frame 19

3.2 Working principles, Layout and design 20-21

3.2.1 Basic layout 20

3.2.2 Working principles 21

3.2.3 Design & Construction 21

3.3 Assembly 22-24

CHAPTER 4: WORKING 25-28

4.1 Wash cycle 26

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4.2 Washing 26

4.3 Rinsing 27

4.4 Spinning 28

CHAPTER 5: COST ANALYSIS 29

CHAPTER 6: CONCLUSIONS 31

FUTURE DEVELOPMENTS 32-34

Use of chair in place of cycle frame 32

Welded steel structure 32

Technology for the poor 33

REFERENCES 35

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LIST OF TABLE

Table No. Name of Table Page No.

3.1 Dimensions of different

components of the model

19

3.2 Operating Parameter 29

5.1 Cost Estimation 30

12

LIST OF FIGURES

Figure

No.

Figure Name Page No.

Fig. 1.1 Pedal powered washing machine (PPWM) 1

Fig. 1.2 Women Washing Laundry in Guatemala. Currently, Women

Wash and rinsing out each Clothing Item Individually By

Hand.

4

Fig. 2.1 Pedal Operated Washing Machine 6

Fig. 3.1 Seat 7

Fig. 3.2 Pedal Arrangement 8

Fig. 3.3 Pedal & Sprocket with teeth 9

Fig. 3.4 Pedal & Sprocket 9

Fig. 3.5 Bearing 10

Fig. 3.6 Chain & sprocket 11

Fig. 3.7 Chain 11

Fig. 3.8 Chain arrangement 11

Fig. 3.12 Single Speed (Top) And Multi-Speed (Bottom) 12

Fig. 3.9 Separated Chain 13

Fig. 3.10 This Chain Is Too Thin For The Teeth 14

Fig. 3.11 Catcher & Sprocket 15

13

Fig . 3.12 Shaft 15

Fig. 3.13 Inner drum : Drum As A Washing Chamber 16

Fig. 3.14 Outer drum: Drum As A Washing Chamber 16

Fig. 3.15 Cycle frame arrangement 19

Fig. 3.16 Welding 20

Fig. 3.17 Wooden base frame 21

Fig. 3.18 Layout of PPWM 21

Fig. 3.19 Assembly of cycle frame 22

Fig. 3.20 Assembly of compound gears 23

Fig. 3.21 Assembly of housing 24

Fig. 4.1 Washing of clothes 26

Fig. 4.2 Washing chamber 28

Fig. A Operating a wood working lathe 32

Fig. B Operating a circular saw 33

Fig. C Water pumping through a shallow well 33

Fig. D Corn shelling 33

Fig. E Winnowing 34

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CHAPTER: 1 INTRODUCTION

1. 1: THEORY

Pedal power washing machine is the transfer of energy from a human source through the use

of a foot pedal and Gear system. This technology is most commonly used for

transportation and has been used to propel bicycles for over a hundred years. Some

third world development projects currently transform used bicycles into pedal powered tools

for sustainable development.

An individual can generate four times more power (1/4 HP) by pedaling than by hand-

cranking. At the rate of ¼ HP, continuous pedaling can be served for only short periods,

approximately 10 minutes. However, pedaling at half this power (1/8 HP) can be sustained

for close to 60 minutes but power capability can depend upon age. As a consequence of the

brainstorming exercise, it was apparent that the primary function of pedal power one specific

product was particularly useful the bicycle.

Fig 1.1 Pedal Powered Washing Machine (PPWM)

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A pedal-powered washing machine would allow women to wash clothes faster and with

less strain. When asked what they would do with their free time, women said that they

would try to generate income by making crafts or food to sell. Young daughters who help

their mothers with domestic chores may also have the opportunity to concentrate more on

their studies. Laundromat micro-enterprises may even arise if our washing machines are

successful. Conditions vary in developing countries, but women in many regions are

washing clothes manually while they could be doing more profitable or rewarding work

elsewhere.

Several local organizations across Central America and Africa have already expressed an

interest in pedal-powered technology. It is an affordable, environmentally-friendly

alternative to devices powered by electricity or fossil fuels. Since it is based on bicycle

components, the machines can be manufactured locally and repair parts are affordable and

readily available. We are hoping that designed to be produced and maintained in any

culture where bicycle technology exists, will help to bring appropriate technology and

opportunities to women in developing nations across the world and pave the way for other

pedal-powered or appropriate technologies that would help women.

1. 2: Innovation

Pedal powered washing is a machine which does not require electricity for several

operations like washing, drying, rinsing etc. This is a human powered machine runs on

gear drives mainly with human efforts. It has some special attachment so use both human

power as well as electric power. The design is ideal for use in the developing world

because it doesn’t require electricity and can be built using metal base, chain, pulley

,rubber belt, bearing, foot pedal (for operated by human).

Washing the clothes is very specific to particular cultures, but most cultures perform the

task in the same way. In almost all underdeveloped rural areas, due to the lack of money

problem. Women wash clothes by hand, using cold or lukewarm water that they carry from

a river or pull up from a well which is a very difficult task. Existing technologies for

washing clothes do not work well in underdeveloped rural areas.

Lack of electricity make powered machines unusable. Difficult transportation due to poor

road conditions or just geographical distances create problems with imported devices that

might need replacement parts or maintenance repairs.

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clothes washing problem in an efficient, affordable and practical way. To our knowledge,

no one has successfully built a pedal powered washing machine (multi utility drum) with

these goals in mind.

1. 2: Ease of Use

It will be easy to use by younger and older person. After loading the machine, washing

requires three cycles. Between each cycle, the drum spins quickly to draw the water out of

the clothing, as it drains out of the drum. In the first cycle, water and detergent are added to

the drum. The operator pedals the machine for roughly 25 minutes, spins, and drains the

water.The next two cycles are rinse cycles. In each rinse cycle, the operator pours clean

water into the machine, pedals for 10 minutes, spins, and drains the drum. After the last

rinse cycle, the operator spins the clothes dry and saves the slightly soapy water for the

next wash cycle.

Our research into existing washers and our earlier prototypes indicate that the power

required for washing, drying and spinning is relatively low. We demonstrated that it is not

difficult to spin a perforated plastic drum up to extraction speeds with clothes inside. For

these experiments, we used a geared transmission from a bicycle. Both younger and older

women can generate enough power for the wash and spin cycles. We estimate this power

to be 50-75 watts. While familiarity with pedaling in general and the machine in particular

will reduce the effort expended by the user, no prior experience will be necessary for its

operation. The ability to change gearing ratios will allow some level of tuning to individual

users and also allow for shorter wash times with more power input or conversely less

strenuous operation if the user can pedal for a longer amount of time.

1.4: NEED

In developing countries, rural women are among the least privileged. Women are both

essential to the family unit and integral to the economy,. One factor behind the inequality

is the long list of responsibilities that traditionally fall to women. Not only do women

perform agricultural duties and care for livestock alongside men, but women are also

responsible for many domestic chores. Usually, new technology improves people’s

efficiency, but women benefit less from new technology for several reasons. First,

women’s duties are neglected by technological improvement efforts because domestic

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chores are often seen as cultural obligations for women so little effort is expended to

diminish them. Second, foreign aid in the form of appropriate technologies is unevenly

distributed because women are often considered less technically competent than men.

Factors like these tend to prevent the development of improved technology for women’s

uncompensated, time-consuming, and laborious

Fig 1.2 Women Washing Laundry in Guatemala. Currently, Women Wash and rinsing out each

Clothing Item Individually By Hand. They Must Bend Over The Tanks And Submerge Their Hands In

Washing Solution For 8 Hours Each Week (ref. 9)

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CHAPTER: 2 LITERATURE SURVEY

2.1: Literature survey of the pedal powered washing machine

The Pedal Powered washing machine is working on compound gear system. The PPWM is

used to washing, drying, rinsing. PPWM helps to obtain a less effort uniform sinning and

washing. It can be used in places where Electricity is not available. It is designed as

portable one which can be used for rising and washing in various Places. By pedaling the

bicycle the pedaling motion rotates the drum, the washing machine will be moving with

the crank & rotate the multi utility drum for the washing. Thus the light material can be

also washing the clothes without any external energy like fuel or current. Since this uses no

electric power and fuel, this is very cheap and best.

The surveys of the literature regarding the PPWM are listed

2.1.1 Dharwa chaitanya kirtikumar [2] designed and developed a multipurpose machine

which does not require electricity for several operations like washing. This is a human

powered machine runs on gear drives mainly with human efforts. But if you wanted to

operate this machine by electric power this machine can also does that. It has some special

attachment so use both human power as well as electric power. The design is ideal for use

in the developing world because it doesn’t require electricity and can be built using metal

base, chain, pulley ,rubber belt, bearing, foot pedal (for operated by human) , chain socket.

2.1.2 S.G.bahaley, Dr. Ague, Awate, S.V. saharkar [3] designed and fabricated a pedal

powered multipurpose machine. It is a human powered machine which is developed for

lifting the water to a height 10 meter and generates 14 Volt, 4 ampere of electricity in most

effective way. Power required for pedaling is well below the capacity of an average

healthy human being. The system is also useful for the work out purpose because pedaling

will act as a health exercise and also doing a useful work.

2.1.3 Linxu, Weinan bai, Jingyu rue, and Qiang li [4] designed and developed an pedal

driven washing machine, The main objective is to provide a product with an alternative

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way to wash clothes when there is no electricity. It has to be understood that in rural areas,

it is a very stressful and laborious task. So the machine which is a pedal driven machine, it

satisfies the need of rural people by giving them an alternative way of washing clothes

which is quick, cost-effective and eco-friendly. The product designed has zero operating

cost, cost-effective, and it can be used with minimal.

This study aims to design and fabricate a pedal driven washing machine to obtain a less

effort uniform washing and sinning and to have a comparison between hand driven and

pedal driven washing machine.

Fig 2.1 Pedal Operated Washing Machine

2.2: Project Objectives:

The title of this project work is “Design & fabrication of pedal powered washing

machine”. The objectives of the present work are:

Study on washing machines on the basis of design & construction, performance,

economy and applications.

Design & construction a working unit of low cost washing machine made up of

easily and readily available scrap parts in daily life. It generates power through

human pedalling and with the drive mechanism, to perform all the functions such

as Washing, Rinsing, and Spinning.

Cost analysis of a unit of pedal powered washing machine

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CHAPTER: 3 DESIGN & CONSTRUCTION OF PPWM

3.1 Components and their technical Features

3.1.1: Seat

A seat is place to sit, often referring to the area one sits upon as opposed to other elements

like armrests. Seat is a arrangement in any bicycle on which a person can sit comfortably.

In seating arrangement the design factor is always consider according to their use in any

vehicle. Seat may be made of plastic, rubber, metal etc material. In some seating

arrangement suspension is also consider.

Fig3.1 Seat

3.1.2: PEDAL ARRANGEMENT

A bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel the

bicycle. It provides the connection between the cyclist's foot or shoe and the crank

allowing the leg to turn the bottom bracket spindle and propel the bicycle's wheels. Pedals

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usually consist of a spindle that threads into the end of the crank and a body, on which the

foot rests or is attached, that is free to rotate on bearings with respect to the spindle.

Pedals were initially attached to cranks connecting directly to the driven (usually front)

wheel. The safety bicycle, as it is known today, came into being when the pedals were

attached to a crank driving a sprocket that transmitted power to the driven wheel by means

of a roller chain.

Fig 3.2 Pedal Arrangement

3.1.3: GEAR

Bicycle gearing is the aspect of bicycle drive train that determines the relation between the

cadence, the rate at which the rider pedals, and the rate at which the drive wheel turns.

On some bicycles, there is only one gear and the gear ratio is fixed. Many contemporary

bicycles have multiple gears and thus multiple gear ratios. A shifting mechanism allows

selection of the appropriate gear ratio for efficiency or comfort under the prevailing

circumstances: for example, it may be comfortable to use a high gear when cycling

downhill, a medium gear when cycling on a flat road, and a low gear when cycling uphill.

Different gear ratios and gear ranges are appropriate for different people and styles of

cycling.

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A cyclist's legs produce power optimally within a narrow pedaling speed range, or

cadence. Gearing is optimized to use this narrow range as best as possible. As in other

types of transmissions, the gear ratio is closely related to the mechanical advantage of the

drive train of the bicycle. On single-speed bicycles and multi-speed bicycles using

derailleur gears, the gear ratio depends on the ratio of the number of teeth on the chain ring

to the number of teeth on the rear sprocket (cog). For bicycles equipped with hub gears, the

gear ratio also depends on the internal planetary gears within the hub. For a shaft-driven

bicycle the gear ratio depends on the bevel gears used at each end of the shaft.

For a bicycle to travel at the same speed, using a lower gear (larger mechanical advantage)

requires the rider to pedal at a faster cadence, but with less force. Conversely, a higher gear

(smaller mechanical advantage) provides a higher speed for a given cadence, but requires

the rider to exert greater force. Different cyclists may have different preferences for

cadence and pedaling force. Prolonged exertion of too much force in too high a gear at too

low a cadence can increase the chance of knee damage; cadence above 100 rpm becomes

less effective after short bursts, as during a sprint.

Fig 3.4 Pedal & sprocket

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3.1.4: BEARING:

A bearing is a machine element that constrains relative motion between moving parts to

only the desired motion. The design of the bearing may, for example, provide for

free linear movement of the moving part or for free rotation around a fixed axis; or, it

may prevent a motion by controlling the vectors. Bearings are classified broadly

according to the type of operation, the motions allowed, or to the directions of the loads

(forces) applied to the parts.

Fig 3.5 Bearings [8]

The term "bearing" is derived from the verb "to bear" a bearing being a machine element

that allows one part to bear (i.e., to support) another. The simplest bearings are bearing

surfaces, cut or formed into a part, with varying degrees of control over the form,

size, roughness and location of the surface. Other bearings are separate devices installed

into a machine or machine part. The most sophisticated bearings for the most demanding

applications are very precise.

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3.1.5: CHAIN AND SPROCKET

When creating your own human powered vehicles, a chain drive will likely be your

chosen power transfer system, as it is an inexpensive, easy-to-install and highly efficient

drive mechanism. Bicycle chains are fairly simple, requiring only one inexpensive tool to

remove and attach links. Since a recumbent cycle will often require a chain that is one

and a half to 3 times the length of a regular upright bicycle chain, some basics should be

known, as you will probably need to create the chain for your vehicle.

Fig 3.6 Chain [8]

Fig 3.7 Chain arrangement

There are two basic types of bicycle chain: single speed chain and multi-speed chain.

Single speed chain is mainly used on kids' bikes, BMX bikes, coaster brake cruisers, and

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heavy cargo bikes. Multi-speed chain is used on standard speed bikes and mountain

bikes that require the use of a front and rear derailleur to change gears. Both types of

bicycle chain have a pitch of 1/2 inch (ANSI standard #40). This measurement indicates

the length of the links. Although every type of bicycle chain and freewheel have a 1/2 in

pitch, the width of chain varies quite a bit, from 3/32" to 1/8". Single speed bicycle

chain is wider, having a width of 1/8 inch. This type of chain will not fit a multi-speed

freewheel nor will it fit properly through a derailleur cage. Multi-speed chain comes in

variouswidths, with 3/32" being the most common size. Multi-speed chain is designed

with a lot more side-to-side flex to allow it to function properly with a derailleur system.

Flexibility is very important in a multi-speed system as the alignment of front and rear

chain rings could be off by as much as 3 inches, depending on which gears are being

used. Figure 1 shows the two common sizes of bicycle chain; 1/8" on the top and 3/32"

on the bottom. At this angle, both chain types look very similar since you can only see

the pitch, not the width.

Fig 3.8 Single speed (top) and multi-speed (bottom)[11]

Figure 3.8 gives you a much clearer view of the difference between a 1/8" single speed

chain (top) and a 3/32" multi-sped chain (bottom). The multi-speed chain is obviously

narrower to fit the narrower chain rings on a multi-speed freewheel, and it also includes a

beveled edge on the inner link to allow for better meshing with the teeth when switching

gears.

When bicycle building becomes your hobby, one of those "must have" tools will be a

chain link tool as shown in Figure. For under $20, this small tool will give you a lifetime

26

of service, able to break and rejoin any size of bicycle chain in a few seconds. The other

method involves using a punch, a hammer, and a finishing nail, but I assure you, the

chain link tool is so much easier and makes a worthwhile investment. To open a link,

place the chain into the holder as shown in Figure 3, and then turn the vice handle

clockwise to press out the link pin.

The link pin pushed out by the chain link tool after turning the handle around a few

times. This tool makes adjusting a chain pretty much effortless which is a good thing

since you may have to adjust a long recumbent chain on a new project several times to

get it right.

Fig 3.9 Separated Chain[11]

After breaking a chain with the link tool, it will look like the one shown in Figure , with

the link pin pressed through the roller to the outer plate. The pin only needs to be pressed

far enough out so that the roller can be released. Notice that the pin has been slightly

flattened at the end. This helps to ensure that it does not slip out of the plate hole, which

is only holding it there by friction. I have broken many chains over the years, but it has

always been a plate that has snapped, never a pin that has fail.

The two outer plates, pins, and rollers with inner plates are shown in Figure 6. Normally,

you would not need to pull a chain apart like this, as there are no wear parts that can be

replaced. When a chain fails or stretches, the damage is always throughout the entire

chain, which needs to be replaced. For this reason, you should never join together chains

that are from different manufacturers or may be years apart in wear. Often, the outer

plates will have the manufacturers’ code stamped on them.

After pressing a link back into a chain, the pin will have forced the plates together,

27

causing a stiff link as shown in Figure 7. This stiff link will cause a skip or jump every

time it passes through the rear derailleur, and must be fixed before use. A stiff link will

always be created when first joining a chain, but it can easily be relaxed.

To fix a stiff link, hold the chain so you can work the links side to side as shown in

Figure 8. Press your thumbs against the plates on each side of the stiff link and force it

back and forth until it no longer sticks when you bend the chain. Once the link has been

relaxed, it will act like every other link without causing the problem. A common 6 speed

freewheel and the 3/32" chain that fits into it. Although the larger single speed (1/8")

chain will also fit into the teeth, it will be too wide to fit properly through the rear

derailleur. You could get away with the larger chain on a multi-sped freewheel if you

plan to make your bike single speed (fixed gear).

The 3/32" multi-speed chain is not only designed to fit properly between the rear

derailleur cage as shown in Figure, but it is also designed to flex side-to-side, allowing

some misalignment between opposing chain rings at the front and rear of a bicycle.

Fig 3.10 This chain is too thin for the teeth[11]

Multi-speed chain will not fit into the teeth of a single speed free hub or coaster hub as

shown in Figure 11, so you don't ever have to worry that you may have the wrong chain

there. The width of the teeth makes it impossible to seat the rollers properly. The 1/8"

single speed chain is shown meshing with a BMX freewheel in Figure 12. A coaster hub

28

will have the same width of chain ring, requiring the 1/8" wide chain. Sometimes, you

may require a very long chain when making a long cargo trike or even a very tall bike.

The chain shown in Figure 13 is standard 1/8" single speed chain, but was taken from a

discarded garage door opener, a good source for a very long length of single speed

chain. When working on recumbent cycles and creative human powered vehicles, you

will likely need to join together two or more bicycle chains, so consider purchasing an

inexpensive chain link tool, and be mindful of the different widths of bicycle chain.

Rusty chain should always be discarded. Oiling a chain is a matter of choice. I have

never oiled a bicycle chain, and the current school of thought is that an oiled chain is less

efficient and will wear out sooner due to trapping dirt between the links. Maybe if your

bike lives outdoors and is exposed to alot of moisture, then a light brushing of light oil

may be a good thing.

3.1.6: CATCHER

Catcher is a part of rickshaw on which sprocket could be mount. on it threaded design is

made .by using it sprocket could be tighten.

Fig 3.11 Catcher & sprocket[12]

3.1.7 SHAFT

Shaft is a mechanical component for transmitting torque and rotation, usually used to

connect other components of a drive train that cannot be connected directly because of

distance or the need to allow for relative movement between them. Drive shafts are

carriers of torque: they are subject to torsion and shear stress, equivalent to the difference

between the input torque and the load. They must therefore be strong enough to bear the

29

stress, whilst avoiding too much additional weight as that would in turn increase their

inertia. To allow for variations in the alignment and distance between the driving and

driven components, drive shafts frequently incorporate one or more universal joints, jaw

couplings, or rag joints, and sometimes a splined joint or prismatic joint.

Fig 3.12 Shaft [9]

3.1.8: SHAFT COLLAR

The shaft collar is a simple, yet important, machine component found in many power

transmission applications, most notably motors and gearboxes. The collars are used as

mechanical stops, locating components, and bearing faces. The simple design lends itself

to easy installation. Many people will be familiar with shaft collars through using

Meccano.

3.1.9: DRUM AS A WASHING CHAMBER

It is just a chamber in which water is filled with detergent further cloth is put inside it for

rinse. In this type of machine, there are two drum are used: inner & outer.

Inner drum: This drum consists of clothes & it is less in diameter as compared to outer

drum. Inner drum is blanked throughout its body. It rotates with the help of compound

gear & chain arrangement in the desired speed with respect to the purpose.

Outer drum: Outer drum is used to store water used for washing the clothes.

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Fig 3.13 Inner drum

Fig 3.14 Drum as a washing chamber (OUTER)

DESING ANALYSIS:

Cleaning:

Machine-washed clothes must be as clean as those hand-washed for 5 minutes

Gentleness:

Must wear clothes at slower rate than hand-washing [hole/tear growth]

Capacity:

Minimum 5lb of clothes/load – should be easy to re-size.

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Water:

Effective washing must occur in soft and hard water at temperatures from 70-120_F

Water usage:

Maximum 5L water / .5kg clothes

Active pedaling time for effective washing:

Maximum 20 minutes each for wash and rinse cycles

Total operation time:

Maximum 1 hours, including fetching water, filling, washing, draining, and cleaning

machine

Power:

Maximum 100W (comfortable level of human-power output)

Cost:

Rs. 7000 (comparable to cost of other MP machine)

Lifetime of structure:

5 years, assuming daily use

Manufacturing location:

local market

Weight:

Maximum 10kg, or 25kg if it has wheels (1 woman can move it indoors so it can’t be

stolen or damaged).

Culturally acceptable:

Suitable appearance, user position and motion such that most women are willing to use

the machine.

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Table 3.1. Dimensions of different components of the model

S. NO. PARAMETERS DIMENSION (mm)

1. Inner drum diameter 180

2. Outer drum diameter 300

3. Length of inner drum 230

4. Height of shaft 690

5. Distance between shaft & cycle 380

6. Height of base above ground 18

7. Length of base 670

8. Width of base 380

9. Height of seat 810

10. Height of handle 1067

11. Total volume of inner drum 19782000

12. Total volume of outer drum 5849820

13. Length of outer drum 280

14. Distance B\W Sprocket & pedal 360

3.1.10: CYCLE FRAME ARRANGEMENT

A bicycle frame is the main component of a bicycle, on to which wheels and other

components are fitted. The modern and most common frame design for an upright

bicycle is based on the safety bicycle, and consists of two triangles, a main triangle and a

paired rear triangle. This is known as the diamond frame. Frames are required to be

strong, stiff and light, which they do by combining different materials and shapes.

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Fig 3.15 Cycle frame arrangement

3.2 FABRICATION PROCESS USED IN THE PROJECT:

3.2.1 WELDING

Cast iron can be welded perfectly well using a stick welder and nickel rods, or with

preheating by a gas welder using cast iron rod. Welding cast iron is a precision task that

requires high heat, and often expensive equipment. You should not attempt it on the

strength of reading a brief Internet article, no matter how informative. However,

understanding the basics can help you prepare for a qualification course, or to make

better decisions for welding projects run by qualified personnel under your supervision.

TIPS

Always preheat or precool cast iron using the same method throughout. Changing

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methods can cause stress and fractures in the cast iron. These may ruin your

project, or be small enough to go unnoticed until the iron fails catastrophically

during normal operation.

Cast iron is typically higher in carbon than steel. This makes the iron brittle, and more

difficult to weld than other industrial metals.

Fig 3.16 Welding [10]

DIMENSION OF THE BASE FRAME

Length:- 670 mm

Width:- 379mm

Thickness:- 18mm

Material used: Wood

Fig 3.17 Wooden base frame

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3.2 BASIC LAYOUT, WORKING & ASSEMBLY:

3.2.1 LAYOUT OF PPWM:

PPWM consist of no. of components such as Drum, gear, shaft, chain, paddle, sprocket,

seat etc .Each & every component has its specific work.

Fig. 3.18 Layout of PPWM

PRINCIPLE: It is a machine which generates power through human pedaling and

with the drive mechanism, converts the pedaling motion into required rotary motion of

the drum. Its innovation lies in its simple design, use of inexpensive parts. With the help

of compound gear system, the machine achieves the desire speed for different purposes

like rinsing, drying etc.

3.2.2 Operating Parameter

Operating Parameter for a normal human being , These are the operating parameter:

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3.3 ASSEMBLY: The assembly of PPWM involves number of steps, these are started

from the frame of cycle which is the initial part of the structure:

STEP 1: The cycle frame consist of sprocket, chain, catcher, pedal, etc. With the help of

Gas welding, the stand & seat is welded to the frame of cycle. The seat & stand are made

of mild steel. The pedaling gear is connected to the sprocket with the help of chain.

Fig 3.19 Cycle frame

STEP 2: The catcher contains one more gear (i.e. freewheel) of bigger diameter. The

sprocket & freewheel are mounted on the same shaft, So the speed of sprocket &

freewheel are same. This big gear transfer this rotary motion to the another gear which is

much smaller than this gear.

STEP 3: This assembly of 4 gear with chain is known as COMPOUND GEAR

SYSTEM. This small gear is coupled with washing chamber (i.e. drum) by using

fasteners. In this type of arrangement, the output is much larger than the input given in

the form of pedaling motion. For this PPWM, there is the ratio of I/p & O/p is 1:9.

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.

Fig 3.20 Compound gear system

STEP 4: There are two drums are mounted on that output shaft; outer & inner drum. The

inner drum contains clothes and water & it rotates in the same speed that of gear. The

outer drum consists of water only & it is stationary. The inner drum rotates freely

without any obstacle.

STEP 5: The wooden base frame comprises of this whole arrangement. The nuts & bolts

are used to fix this assembly and it gives the rigidity to the whole structure.

STEP 6: To give the aesthetic appearance to the machine, the wooden ply board is used

to make the housing. This housing protects the outer drum perils of outsiders.

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Fig 3.21 Housing of PPWM

For washing, the speed is quite low i.e. 30-40rpm & for drying, the higher speed i.e.800-

900 rpm is required. This speed can be attaining by a normal woman & men.

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CHAPTER: 4 WORKING OF PPWM

WORKING:

A washing machine (laundry machine, clothes washer, or washer) is a machine to wash

laundry, such as clothing and sheets. The term is mostly applied only to machines that

use water as opposed to dry cleaning (which uses alternative cleaning fluids, and is

performed by specialist businesses) or ultrasonic cleaners. Washing entails immersing,

dipping, rubbing, or scrubbing in water usually accompanied by detergent, or bleach.

The simplest machines may simply agitate clothes in water while switched on; automatic

machines may fill, empty, wash, spin, and heat in a cycle. Most washing machines

remove substantial amounts of water from the laundry at the end of a wash cycle, but do

not completely dry it.

In our project the rotation of drum is possible through wheel rotation .Wheel is rotated

by chain drive. When a person start peddling, the gear connected through sprocket by

chain start to transmit power, the rotation of drum is dependent on man power. In our

project the complete process is depend on compound gear system. Gear drive is a way of

transmitting mechanical power from one place to another. It is often used to convey

power to the wheels of a vehicle, particularly bicycles and motorcycles. It is also used in

a wide variety of machines besides vehicles.

Most often, the power is conveyed by a roller chain, known as the drive chain or

transmission chain, passing over a sprocket gear, with the teeth of the gear meshing with

the holes in the links of the chain. The gear is turned, and this pulls the chain putting

mechanical force into the system. Another type of drive chain is the Morse chain,

invented by the Morse Chain Company of Ithaca, New York, USA. This has inverted

teeth.

Sometimes the power is output by simply rotating the chain, which is used as input for

the washing drum. In other situations, a second gear is placed and the power is recovered

by attaching shafts or hubs to this gear. Though drive chains are often simple oval loops,

they can also go around corners by placing more than two gears along the chain; gears

that put power into the system or transmit. By varying the diameter of the input and

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output gears with respect to each other, the gear ratio can be altered, so that, for example,

the pedals of a bicycle can spin all the way around more than once for every rotation of

the gear that drives the wheels.

4.1: WASH CYCLES

A stand-alone spin dryer used for extracting water from laundry The earliest washing

machines simply carried out a washing action when loaded with clothes and soap, filled

with hot water, and started. Over time machines became more and more automated, first

with very complex electromechanical controllers, then fully electronic controllers; users

put clothes into the machine, select a suitable program via a switch, start the machine,

and come back to remove clean and slightly damp clothes at the end of the cycle. The

controller starts and stops many different processes including pumps and valves to fill

and empty the drum with water and rotating at different speeds, with different

combinations of settings for different fabrics.

Fig 4.1 Washing of clothes

4.2: WASHING:

Many front loading machines have internal electrical heating elements to heat the wash

water, to near boiling if desired. Chemical cleaning action of the detergent and other

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laundry chemicals increases greatly with temperature. Washing machine with internal

heaters can use special detergents formulated to release different chemical ingredients at

different temperatures, allowing different type of stains and soils to be cleaned from the

clothes as the wash water is heated up by the electrical heater. Higher-temperature

washing uses more energy, and many fabrics are damaged at higher temperatures.

Temperatures exceeding 40 °C have the undesirable effect of inactivating the enzymes

when using biological detergent.

Many machines are cold-fill, connected to cold water only, which they heat to operating

temperature. Where water can be heated more cheaply or with less carbon dioxide

emission than by electricity, cold-fill operation is inefficient.

Front loaders need to use low-sudsing detergents because the tumbling action of the

drum folds air into the clothes load that can cause over-sudsing and overflows. However,

due to efficient use of water and detergent, the sudsing issue with front-loaders can be

controlled by simply using less detergent, without lessening cleaning action.

4.3: RINSING

Washing machines perform several rinses after the main wash to remove most of the

detergent. Modern washing machines use less water due to environmental concerns;

however, this has led to the problem of poor rinsing on many washing machines on the

market, which can be a problem to people who are sensitive to detergents. The Allergy

UK website suggests re-running the rinse cycle, or rerunning the entire wash cycle

without detergent. In response to complaints, many washing machines allow the user to

select additional rinse cycles, at the expense of higher water usage and longer cycle time.

4.4: SPINNING

Higher spin speeds remove more water, leading to faster drying. If a heated clothes-drier

is used after the wash and spin, energy use is reduced if more water has been removed

from clothes. However, faster spinning can crease clothes more. Also, mechanical wear

on bearings increases rapidly with rotational speed, reducing life. Early machines would

spin at only 300 RPM and, because of lack of any mechanical suspension, would often

shake and vibrate.

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Many modern machines are equipped with an automatic clothes load balancer, using a

sealed ring of viscous liquid, that helps to counteract any out-of-balance distribution.

Better machines may include internal suspension and shock systems to reduce noise, and

sensors and software to detect and correct an out-of-balance load.

Separate spin-driers, without washing functionality, are available for specialised

applications. For example, a small high-speed centrifuge machine may be provided in

locker rooms of communal swimming pools to allow wet bathing costumes to be

substantially dried to a slightly damp condition after daily use.

Fig 4.2 Washing chamber

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CHAPTER 5: COST ANALYSIS

The cost estimation cannot be done 100% certainty because price of different material

used in the washing machine are highly fluctuating. In this work, a rough estimation of

the cost is being reported on the basis of market survey. Approximate cost of different

components are given in table 5.1:

Table 5.1: Cost estimation

S. NO. NAME OF THE COMPONENT QUANTITY ESTIMATED COST

(Rs.)

1. Wooden board 1 500

2. Drum 2 400

3. Iron pipe & stand 1 1500

4. Cycle frame 1 1200

5. Gear set 2 1000

6. Pedal set 1 500

7. Chain set 2 800

8. Flywheel 1 500

9. Nut bolts As per need 100

10. Pipe , socket, bracket 500

11. Overhead 1000

12. Total cost 8000

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CHAPTER 6: CONCLUSIONS

A pedal-powered washing machine would allow women to wash clothes faster and with

less strain. It can be use by man, woman, old people etc. When asked what they would

do with their free time, women said that they would try to generate income by making

crafts or food to sell. Young daughters who help their mothers with domestic chores may

also have the opportunity to concentrate more on their studies. Laundromat

microenterprises may even arise if pedal powered washing machines are successful.

Conditions vary in developing countries, but women in many regions are washing

clothes manually while they could be doing more profitable or rewarding work

elsewhere. It is also helpful for maintaining fitness.

We hope through our research and analysis we have designed or at least help clarify the

design - concept of a pedal-powered washing machine. Hopefully in the near future, such

helpful tools become a common addition to Cambodia villages and Third world

countries.

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FUTURE DEVELOPMENT

A. USE OF CHAIR IN PLACE OF CYCLE FRAME

For making perfect washing of clothes more comfortable, the cycle frame can be

replaced with a chair. Use of chair will be more convenient for women as well.

B. COMPOSITE STRUCTURE

To reduce the assembly time and prevent others from tampering with it in

public areas, the structure will be made out of welded angle iron. Welding fixtures may

be designed to make it easier to weld several structures with proper alignment of

components. The welded structure will add to the weight of the machine, making it

inherently less likely to vibrate. The steel structure may also be cemented into the ground

to ensure stability and security of the machine from theft.

C. TECHNOLOGY FOR THE POOR

With the help of this Pedal powered washing machine, there are number

of other technologies are used such as :

C.1 Operating a wood working lathe: The pedaling motion is used to rotate the

wooden work piece & the tool is stationary. In the villages, the small work shop & shops

are run with this low cost machine. It does not required any electricity, so it is one time

investment.

Fig A Operating a wood working lathe[5]

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Fig B Operating a circular saw[6]

These are the some application of pedal powered machine, in which the rotational

motion of cycle is used for cutting the work piece of different materials wood & metal

& non metal .

Fig C Water pumping from a shallow well[6]

It is also used for pumping water from shallow well. The water is pumped to the ground

with the help of pedaling motion. This machine can be used by anyone i.e. men, women,

children etc.

Fig D Corn shelling[5]

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Corn shellor is a piece of machinery to shell corn kernels of the cob for feeding to

livestock or for other uses.

Fig E Winnowing[7]

These are the some application of pedal powered machine, in which the rotational

motion of cycle is used for cutting the work piece of different materials wood & metal

& non metal. There are many developments can be made in future.

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REFERENCES

1. R.S.Khurmi “Design of Machine Elements”, Eurasnia publishing house 3 Pvt Ltd,

14th revised edition.

2. Prof. Nitinchandra R. Patel, Mohammed A. Vasanwala, Balkrushna B. Jani,

Miteshkumar D. Rathwa & Ravi A. Thakkar “Material selection and testing of hacksaw

blade based on mechanical properties’ international journal of innovative research in

science, engineering and technologyvol. 2, issue 6, June 2013

3. S.M.Moghe & K.S.Zakiuddin (2013) “Design and Development of Turmeric

Polishing Machine Energized

4. By Human Power Flywheel Motor.”-A past review, Proceedings of the 1st

International and 16th National

5. Conference on Machines and Mechanisms IIT Roorkee, India, Dec 18-20 2013

6. Bicilavadora: The Pedal-Powered Washing Machine - IDEAS 2005 Proposal.

7. Bruzzone, M. & Wieler, A. (2010) “Reflecting on an Intercultural Design-Build

Project in the Kathmandu Valley” Final Draft, February 5, 2010.

8. http://en.wikipedia.org/washing mc/pedal-powered-washing-machine.htm

9. http://en.wikipedia.org/wiki/Washing machine.

10. http://www.ideafinder.com/history/inventions/washmachine.htm

11. http://home.howstuffworks.com/washer1.htm

12. http://www.apparelsearch.com/definitions/miscellaneous/washing_machine.htm

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